Telescoping boxes, blanks, and systems for pour-style bag-in-box dispensed products

ABSTRACT

Corrugated boxes, box blanks, and systems for individually shipping a bag of liquid stored therein and converting into a bag-in-box dispenser are provided. An example box comprises a top portion with a removable perforation feature defined on a front wall. A bottom portion is sized to fit within an opening of the top portion and includes a cut-out feature in a front wall that aligns with the perforation feature of the top portion when the box is formed. The removed perforation feature and the cut-out feature enable a dispensing valve of a stored bag to extend past/through both front walls when the box is converted into the bag-in-box dispenser. The box is configured to store a bag of liquid ranging from 2 to 10 liters and is designed to pass individual box shipping test standards, such as ISTA and SIOC test standards. Methods of forming the box are also provided.

BACKGROUND

Bag-in-box dispensers provide a user access to dispense liquid product(e.g., soap, oil, cleaner, wine, etc.) from a bag that is held within abox. In some cases, a user accesses a dispensing valve (e.g., opening,nozzle, tap, etc.) on the bag (often extending through a hole in thebox) to dispense liquid from the bag, while the majority of the bag isstored within the box. Conventional box designs for bag-in-boxdispensers include a corrugated box that is designed to be shipped on apallet in an upright orientation (e.g., with other like boxes/product).Then, each bag-in-box product is taken off the pallet for use and/orstocking on a shelf for sale. Notably, shipping and handling under suchcircumstances puts predictable and largely unidirectional stress on thebox such that box designs can afford to be limited while stillmaintaining the box and bag stored inside in working order throughdistribution to the final destination. For example, the strengthcharacteristics for the box can be designed with the knowledge that thebox will only be shipped in the upright orientation.

BRIEF SUMMARY

Embodiments of the present invention are directed to corrugated boxdesigns that are designed to withstand the individual e-commerceshipping environment, which includes the same shipping and handling thatoccurs for other types of boxes in this environment (e.g., throwing theboxes, dropping the boxes in all orientations, vibration within atransport vehicle with weight stacked on top). Importantly, in theindividual e-commerce shipping environment, there is no predictableorientation for the box design, and all of the above (and other)circumstances occur in all orientations. Thus, while prior box designsfor bag-in-box dispensers could predict their orientation (e.g.,upright) and had the benefit of relatively safe/professional handlingand transfer, the present invention takes into account all of thoseuncertainties and likely occurrences to still deliver an intact box tothe final destination.

For bag-in-box products, it is very important to keep the box (and anyperforations) intact during shipping because otherwise the liquidproduct in the bag may spill out if the bag breaks, rips, or tears, asthe bag is more susceptible to breaking and/or leaking if the box iscompromised/weakened. That situation is of extra concern because spilledliquid can cause significant damage to other boxes or transportationequipment (e.g., trucks, conveyors, warehouse flooring, etc.) duringshipping and is difficult to clean (e.g., in comparison to non-liquidproducts being shipped). In this regard, the box designs of the presentinvention are engineered to withstand and pass various standardizeddistribution sequences that are specifically designed to replicate harshconditions that a box goes through during individual e-commerce shipping(e.g., through various known consumer-based shipping services). Suchexample safety test standards include the International Safe TransitAssociation (ISTA) test standards, including the Ship In Own Container(SIOC) test protocols. In such a regard, the resulting box designs ofthe present invention are the product of significant testing, as manyother designs were disregarded after failing such tests.

Embodiments of the present invention provide example box designs forsafely and successfully transporting a bag of liquid and still enablingconversion into a bag-in-box dispenser, where the bag-in-box dispenseris designed to enable pouring of the liquid product therefrom. Forexample, a user may be able to hold the box (now converted into thebag-in-box dispenser), tip it, and pour the liquid out from a dispensingvalve that extends through a front wall of the box. Such example liquidincludes floor cleaner, wine, juice, coffee, among other liquids thatcan be poured. Notably, the various box designs described herein aredesigned to hold a bag of liquid with volume ranging from 2 liters to 10liters (though other ranges are contemplated) and/or a weight rangingfrom approximately 5 lbs. to 25 lbs. (though other ranges arecontemplated). In some embodiments, such box designs may utilizetelescoping half-slotted containers (HSCs), although embodiments of thepresent invention are not meant to be limited to such a box design. Inthis regard, notably, embodiments of the present invention provide a boxdesign with various features that are designed to aid in safe transportof the stored bag, while still providing for the conversion into auseful bag-in-box dispenser at the point of intended product usage.

To achieve such a goal, some embodiments of the present inventionprovide a box design with a top portion and a bottom portion. The topportion includes a perforation feature defined on the front wall,wherein the perforation feature is defined by a series of perforationsand is removable from a remainder of the front wall. The perforationfeature is configured to enable a dispensing valve of the bag to extendpast or through the front wall of the top portion when the box isconverted into the bag-in-box dispenser. The bottom portion includes acut-out feature in the front wall that aligns with the perforationfeature. The cut-out feature may be shaped to hold a dispensing valve(e.g., opening) of the bag once the bag-in-box dispenser is converted.In this regard, upon arrival at the final destination, a user may removethe perforation feature, lift up the top portion (e.g., slightly) fromthe bottom portion and arrange the dispensing valve into the cut-outfeature, and then reposition the top portion over the bottom portion soas to convert the box into the bag-in-box dispenser with the dispensingvalve available for use (e.g., for pouring out liquid from the bag).Various additional features, such as a second perforation feature andcorresponding handle on the back wall, finger access portions,positioning of a side flange, among others described herein, arecontemplated for some embodiments, and may aid in providing safetransport of the stored bag, while still providing for easy conversioninto a useful bag-in-box dispenser upon arrival at the finaldestination.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 shows a front, top perspective view of an example corrugated box,in accordance with some embodiments discussed herein;

FIG. 2 shows a rear, top perspective view of the example corrugated boxshown in FIG. 1, in accordance with some embodiments discussed herein;

FIG. 3 shows a front, top perspective view of a bottom portion of theexample corrugated box shown in FIG. 1, in accordance with someembodiments discussed herein;

FIG. 4 shows a rear, top perspective view of the bottom portion of theexample corrugated box shown in FIG. 1, in accordance with someembodiments discussed herein;

FIG. 5 illustrates a layout of a box blank for the example corrugatedbox shown in FIG. 1, in accordance with some embodiments discussedherein;

FIG. 6 illustrates an example method of converting an example corrugatedbox into a bag-in-box dispenser, in accordance with some embodimentsdiscussed herein;

FIG. 7 shows a front, top perspective view of the example corrugated boxshown in FIG. 1, wherein a first perforation feature has been removed,in accordance with some embodiments discussed herein;

FIG. 8 shows a rear, top perspective view of the example corrugated boxshown in FIG. 1, wherein a second perforation feature has been removed,in accordance with some embodiments discussed herein;

FIG. 9 shows an example top portion of a corrugated box displaced abovean example bottom portion of the corrugated box, wherein the first andsecond perforation features have been removed, in accordance with someembodiments discussed herein;

FIG. 10 shows a front, top perspective view of the example corrugatedbox shown in FIG. 7, wherein the top portion has been lifted up from thebottom portion and a dispensing valve of a bag stored within the box isaccessible for positioning in a cut-out feature of the bottom portion,in accordance with some embodiments discussed herein;

FIG. 11 shows a front, top perspective view of the example corrugatedbox shown in FIG. 10, wherein the dispensing valve has been positionedinto a dispensing position and the top portion has been slid back overthe bottom portion to convert the box into the bag-in-box dispenser, inaccordance with some embodiments discussed herein;

FIG. 12 shows a rear, top perspective view of the example corrugated boxshown in FIG. 11, wherein the box has been converted into the bag-in-boxdispenser with an available handle feature for use, in accordance withsome embodiments discussed herein; and

FIG. 13 illustrates a flowchart of an example method of forming a box,shipping the box with a bag stored therein, and converting the box intothe bag-in-box dispenser, in accordance with some embodiments discussedherein.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafterwith reference to the accompanying drawings, in which some, but not allexample embodiments are shown. Indeed, the examples described andpictured herein should not be construed as being limiting as to thescope, applicability or configuration of the present disclosure. Rather,these example embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Like reference numerals refer tolike elements throughout.

Notably, while some embodiments describe various positional qualifiersfor various features, such as “top”, “bottom”, “front”, “back”, “side”,etc. embodiments described herein are not meant to be limited to suchqualifiers unless otherwise stated. Along these lines, and as anexample, the “top” portion is also contemplated to be a “bottom” portiondepending on the box design/orientation or a “front” wall may be a“side” wall depending on the box design/orientation. The directionalqualifiers herein are generally used to aid in describing the inventionin the context of the drawings and/or description but are not otherwiseintended to be limiting.

While some embodiments describe a “user”, use of such a term herein isnot meant to be limited to a person or a single person, as the “user”may be an end user, a consumer, a manufacturer, among other types ofusers along a supply chain in relation to the box design. Further, whenutilizing the word “user”, the actor(s) may be operating one or moremachines/system that cause the intended function (e.g., forming the boxor converting the box to a bag-in-box dispenser).

Various example embodiments of the present invention provide example boxdesigns for safely shipping a bag of liquid and still enablingconversion into a bag-in-box dispenser from the shipped box, where thebag-in-box dispenser is designed to enable pouring of the liquid producttherefrom. For example, various box designs described herein aredesigned to hold a bag of liquid with volume ranging from 2 liters to 10liters (though other ranges are contemplated) and/or a weight rangingfrom approximately 5 lbs. to 25 lbs. (though other ranges arecontemplated). Some examples of possible liquids that may be shipped insuch quantity include various cleaners and washing liquids, such as maybe poured onto a surface or into bin or other receptacle from thebag-in-box dispenser. However, other example liquids include wine,juice, or any type of liquid that would benefit from being poured fromthe bag-in-box dispenser. Along these lines the term “liquid” usedherein may refer to any type of substance in liquid state (e.g., fluid,creams, lotions, gels, water, etc.).

In some embodiments, such box designs may utilize a version of a boxdesign called a telescoping half-slotted container (HSC), althoughembodiments of the present invention are not meant to be limited to sucha box design. Other example box designs include regular slottedcontainers, wraparounds, overlapping slotted containers, die-cutcontainers, among others. Various embodiments described herein provideone or more features that alone or in combination with each otherprovide a suitable box design for providing safe transport of the storedbag, while still providing for easy conversion of a useful bag-in-boxdispenser upon arrival at the final destination.

Notably, example box designs of the present invention are designed towithstand and pass various laboratory distribution tests that arespecifically designed to replicate harsh conditions a box goes throughduring individual e-commerce shipping (e.g., through various knownshipping services). Such example safety test standards include theInternational Safe Transit Association (ISTA) test standards whichincludes Ship In Own Container (SIOC) test standards, such as the ISTASeries 6-Amazon.com-SIOC test protocol (i.e., the ISTA Series6-Amazon.com-SIOC test for 2018, with a version date with a lasttechnical change in March 2018 and a last editorial change in March2018—where further details are available at www.ista.org). Based on thepackaging weight and/or girth, the box may need to undergo anappropriate Type test (e.g., Type A for under 50 lbs. or Type B for over50 lbs.). For example, the test standards require that the box bepackaged as planned to be shipped and be put through a testing protocolthat includes numerous drops from various heights with the box fallingon different sides (e.g., walls, faces) and edges. This simulatespossible drops that may occur during handling by shipping personnel.Next, the same box undergoes vibration testing that includes prolongedvibration (e.g., for 2.5 hours, although other durations arecontemplated) with weight placed on top of the box—again at specifiedorientations (often required to be on the “weakest” face, e.g., anorientation which the corrugated flutes are not vertically orientedrelative to the applied compression forces). This simulates travelwithin a transport vehicle (e.g., an airplane, train, truck, van, etc.)with other boxes being stacked on top of it. Finally, the same box thengoes through more drops of varying height and on varying sides, corners,or edges, with one of the last drops being at a greater height and onthe “weakest” side or edge. This once again simulates possible dropsthat may occur during handling by shipping personnel. Depending on thedesired outcome, the box may need to pass certain test criteria in orderto pass the tests. Notably, the ISTA Series 6-Amazon.com-SIOC testprotocol acceptance criteria includes (i) the product is fullyfunctional in its intended use, (ii) there are no leaks, (iii) anytamper evidence application is not compromised (e.g., seal integrity isintact), and (iv) any secondary packaging that is considered part of theproduct is free from serious damage/indentations/scratching.

The box may be designed to pass the ISTA Series 6-Amazon.com-SIOC testprotocol or other shipping test protocol (e.g., to be able to ship usingindividual shipping options—such as the mail, truck delivery, etc.), andalso maintain certain form standards that enable it to be converted intothe bag-in-box dispenser upon reaching its final destination. In thisregard, the box should survive (e.g., withstand) the entire test processwhile maintaining a desired form such that the flaps and any perforationfeatures are intact, and with the bag maintained within the box withoutliquid spilling/leaking therefrom, such that the box may be convertedinto a functioning bag-in-box dispenser as intended. In someembodiments, the box may be considered to maintain a desired form evenwith some flexing, but without an undesirable degree of bulging, such asmay include significant changes in the shape of the box to limit itsfunction (e.g., cause perforations to tear or release prematurely, causeflaps to tear or open, cause adhesive joints to fail or openprematurely, cause the box to no longer fit in a designated spot at thefinal destination (e.g., in a storage rack or storage position) or besuitable for stacking or supporting additional loads (e.g., on top ofthe box), prevent full evacuation of the liquid in the bag, causedecreased overall rigidity or integrity of the box to hindertransportation or manipulation of the box). In such a regard, theresulting box designs of the present invention are the product ofsignificant testing, as many other designs were disregarded afterfailing such tests.

An example corrugated box 10 that accomplishes such advantages,including passing the above noted test standards, is shown in FIG. 1.With reference to FIGS. 1-4, the corrugated box 10 is formed of a topportion 20 and a bottom portion 30 (an example top portion 20 and bottomportion 30 are further shown displaced relative to each other in FIG.9).

The top portion 20 comprises four walls (e.g., faces): a front wall 22,a back wall 24, and two opposing side walls 26, 28. Corresponding panels(e.g., a front panel 22′, back panel 24′, a first side panel 26′, and asecond side panel 28′) can be seen in the box blank form of the topportion 20′ shown in FIG. 5. In this regard, the term “panels” may beused when in box blank form and the term “walls” may be used when in theerected/formed box form. As shown, the top portion 20 also includes aside flap 25 (notably, the side flap 25 may be attached to any suitablewall/panel depending on the desired box design). To form the box topportion 20 shown in FIG. 1, the side flap 25 may be attached, such asusing adhesive (although additional or alternative attachment means canbe utilized, such as tape, staples, etc.), to the back wall 24 (althoughother walls can be used depending on the arrangement of the box blank).When formed, the top portion defines an opening 42 (shown in FIG. 9).

With further reference to FIG. 5, the top portion 20 also includes topflaps 27 a, 27 b, 29 a, 29 b that each extend from corresponding panels22′, 24′, 26′, 28′. In particular, a top front flap 27 a extendsupwardly from the front panel 22′; a top back flap 27 b extends upwardlyfrom the back panel 24′; a top first side flap 29 a extends upwardlyfrom the first side panel 26′; and a top second side flap 29 b extendsupwardly from the second side panel 28′. Returning to FIG. 1, the topflaps of the top portion 20 fold from their walls to form a top 87. Inthis regard, the top first side flap 29 a and the top second side flap29 b may fold underneath the top front flap 27 a and the top back flap27 b, and the edges of the top front flap 27 a and the top back flap 27b may meet together or close together, forming a flap gap 82. Althoughshown at a mid-point along a width of the top 87, the flap gap 82 may bepositioned anywhere along a width of the top 87 (e.g., closer to oneside or the other). Likewise, the box design may be formed to includeoverlapping top or bottom flaps. One or more pieces of tape 80 mayextend across the flap gap 82 to form the top 87 (although additional oralternative attachment means can be utilized, such as adhesive, staples,etc.).

The bottom portion 30 comprises four walls (e.g., faces): a front wall32, a back wall 34, and two opposing side walls 36, 38. Correspondingpanels (e.g., a front panel 32′, a back panel 34′, a first side panel36′, and a second side panel 38′) can be seen in the box blank form ofthe bottom portion 30′ shown in FIG. 5. As shown, the bottom portion 30also includes a side flap 35 (notably, the side flap 35 may be attachedto any of the walls/panels depending on the desired box design). To formthe box bottom portion 30 shown in FIGS. 3-4, the side flap 35 may beattached, such as using adhesive (although additional or alternativeattachment means can be utilized, such as tape, staples, etc.), to theoutside of the back wall 34. When formed, the bottom portion defines anopening 43 (shown in FIG. 3) that is sized to receive and store a bag,such as a bag of liquid of volume ranges from 2 liters to 10 liters.Notably, by attaching the side flap 35 to an outside surface of one ofthe walls, the side flap (which contains a rough corrugated edge) isseparated from the stored bag held within the opening 43 of the bottomportion 30 so as to avoid damage to the stored bag during shipping. Offurther note, the bottom portion 30 is sized to be received by and fitwithin the opening 42 of the top portion 20.

With further reference to FIG. 5, the bottom portion 30 also includesbottom flaps 37 a, 37 b, 39 a, 39 b that each extend from correspondingpanels 32′, 34′, 36′, 38′. In particular, a bottom front flap 37 aextends downwardly from the front panel 32′; a bottom back flap 37 bextends downwardly from the back panel 34′; a bottom first side flap 39a extends downwardly from the first side panel 36′; and a bottom secondside flap 39 b extends downwardly from the second side panel 38′. Thebottom flaps of the bottom portion 30 fold from their respective wallsto form a bottom. In this regard, the bottom first side flap 39 a andthe bottom second side flap 39 b may fold underneath the bottom frontflap 37 a and the bottom back flap 37 b, and the edges of the bottomfront flap 37 a and the bottom back flap 37 b may meet together or closetogether along a flap gap that may be covered by one or more pieces oftape (although additional or alternative attachment means can beutilized, such as adhesive, staples, etc.).

With reference back to FIG. 1, the top portion 20 of the corrugated box10 is designed with a first perforation feature 50. The firstperforation feature 50 is defined by a series of perforations 55 a(e.g., weak points) that help a user with removal thereof, such that thefirst perforation feature 50 is removable from a remainder of the frontwall 22 of the top portion 20.

As detailed further herein, the first perforation feature 50 isremovable to help convert the box 10 into a bag-in-box dispenser, suchas shown in FIG. 11. In this regard, a benefit of the first perforationfeature 50 is that it facilitates removal of a portion of the box 10 toallow a user to access a dispensing valve 92 (e.g., opening, nozzle,tap, etc.) on the bag 90 that is held within the box 10 and enablerepositioning of the dispensing valve 92 to a dispensing position, suchas at least partially extending outside of the box 10 (and, thus,accessible by a user for dispensing the liquid from the bag).

In some embodiments, the first perforation feature 50 is aligned with acut-out feature 51 of the bottom portion 30 (described below) and formsan elongated shape that enables a user to at least slightly lift the topportion 20 from the bottom portion 30 and access and reposition thedispensing valve 92. Further, as noted herein, the elongated shape ofthe first perforation feature 50 enables sliding of the top portion 20over the bottom portion 30 even while the dispensing valve 92 is in thedispensing position (e.g., shown between FIGS. 10-11).

In some embodiments, the first perforation feature 50 forms an elongatedshape 54 that extends along a portion of the length of the front wall 22(e.g., shown as length LFW). For example, the first perforation feature50 may have an elongated shape 54 with a first perforation featurelength (LPF) that extends from a position at or above a center position(e.g., a line indicating the approximate center of the length of thefront wall is shown as line C) along the length of the front wall (LFw)toward the bottom edge 23 a of the front wall 22. In some embodiments,the first perforation feature length is greater than a correspondinglength characteristic of the dispensing valve (e.g., the length of thefirst perforation feature may be greater than the diameter of a nozzle91 of the dispensing valve 92—so as, for example, to enable the nozzle91 to be pulled through the opening (e.g., hole) in the front wall 22corresponding to the removed first perforation feature 50). In such aregard, the length of the first perforation feature 50 may be greatenough to enable the top portion 20 to be lifted upwardly from thebottom portion 30 so that a user can pull the dispensing valve 92through an opening formed in the front wall 22 (e.g., by removal of thefirst perforation feature 50). As an example, the first perforationfeature 50 may form an elongated slot type shape. In this regard, suchas with reference to FIG. 10, a user can slightly lift the top portion20, access and reposition the dispensing valve 92 and slightly lower thetop portion 20 back onto the bottom portion 30 with the dispensing valve92 being maintained within the opening formed by the removed firstperforation feature 50. In such a regard, the first perforation feature50 does not need to extend all the way to the bottom edge 23 a of thefront wall 22 in order to enable conversion to the bag-in-box dispenser.

However, in the illustrated embodiment, the first perforation feature 50extends from a position 50 a on the front wall 22 down to the bottomedge 23 a of the front wall 22. In such example embodiments, an addedbenefit is that the top portion 20 can be completely removed from thebottom portion 30 for easy repositioning of the dispensing valve 92 intothe dispensing position and is still able to be slid back over theinstalled dispensing valve 92 that is sticking out past the front wall22. In some embodiments, the first perforation feature 50 defines anelongated shape 54 that may increase in width in a direction leading tothe bottom edge 23 a of the front wall 22 of the top portion 20 tofurther aid in ease of sliding the top portion 20 back over the bottomportion 30 while the dispensing valve 92 is in the dispensing position.

In some embodiments, the width of the first perforation feature 50proximate the bottom edge 23 a of the first wall 22 of the top portion20 may be sized to receive one or more pieces of tape (e.g., see tape 84shown within the width P_(W1) of the first perforation feature 50).Notably, in some embodiments, the tape may extend underneath the box 10(e.g., along the bottom portion 30) and be used to secure the topportion 20 to the bottom portion 30. In some embodiments, a secondperforation feature 56 (such as described herein) may be on the backwall 24 of the top portion 20 and have a width P_(W2) configured toreceive the tape 84. In such embodiments, a user or machine may removethe first and second perforation features 50, 56 and the tape 84. Insome embodiments, a user or machine may remove the first and/or secondperforation features 50, 56 which may result in removal of the one ormore pieces of tape. In some such embodiments, such removal may enableseparation of the top portion 20 from the bottom portion 30.

In some embodiments, the first perforation feature 50 may be spacedapart from a top edge 22 a of the front wall 22 to maintain a desiredrigidity, such that may otherwise be compromised if one or moreperforations (e.g., weak points) were positioned at or too near the topedge 22 a. For example, a top edge 50 a of the first perforation feature50 may be spaced a distance of at least 1 inch from the top edge 22 a ofthe front wall (although other distance ranges are contemplated (e.g.,for boxes with different dimensions), such as at least 2 inches, 3inches, etc.).

Returning to FIG. 1, the top portion 20 may further define a firstfinger access feature 52 (further shown in FIG. 6) positioned adjacentto the first perforation feature 50. The first finger access feature 52may be at least partially defined by a series of perforations 55 b(e.g., a separate series of perforations than the first perforationfeature) and may be removable separately from the first perforationfeature 50 to enable easier access for a user to remove the firstperforation feature 50. Though the first finger access feature 52 isshown defined on the front wall 22, in various embodiments, the firstfinger access feature 52 may be formed on one or more walls or topflaps. Along similar lines, though the first finger access feature 52 isshown as a semi-circle, any suitable shape may be used. With referenceto FIG. 7, like with the first perforation feature 50, a top 79 a of thefirst finger access feature 52 may be spaced apart from a top edge 22 aof the front wall 22, such as shown by D_(FA1).

In some embodiments, the bottom portion 30 of the box 10 may define acut-out feature 51 that further aids in conversion into the bag-in-boxdispenser. For example, with reference to FIGS. 3 and 5, the bottomportion 30 comprises a cut-out feature 51 that defines an absent (e.g.,pre-removed) portion of the front wall 32 of the bottom portion 30. Inthis regard, the cut-out feature 51 may be an area cut-out from thenormal rectangular footprint of the front wall 32 of the bottom portion30 (e.g., in some embodiments the front wall 32 may define acorresponding modified shape (e.g., modified from a normal footprint ofthe wall, such as the opposing back wall 34)—for example, in such aregard, there need not be a cut-out that occurs as the front wall 32could simply be formed with the modified shape). In the illustratedembodiment, the cut-out feature 51 is defined along a top edge 33 a ofthe front wall 32 of the bottom portion 30. The cut-out feature 51 ispositioned on the front wall 32 of the bottom portion 30 to align withthe first perforation feature 50 of the top portion 20 when the bottomportion 30 is received within the top portion 20 (e.g., shown uponremoval of the first perforation feature 50, such as shown in FIGS. 7and 10). In some embodiments, the cut-out feature 51 is configured toenable the dispensing valve 92 to extend past or through the front wall32 of the bottom portion 30 when the box 10 is converted into thebag-in-box dispenser. Along these lines, with reference to FIGS. 10-11,in some embodiments, the cut-out feature 51 (or a portion thereof)defines a shape (e.g., a semi-circle, although other shapes arecontemplated) that corresponds to a portion 91 of the dispensing valve92 such that the cut-out feature 51 at least partially holds thedispensing valve 92 in position when the box 10 is converted into thebag-in-box dispenser. Although shown and described as being pre-removed,in some embodiments, the cut-out feature 51 may be removable such as byusing a series of perforations—such as may be similar to the firstperforation feature 50 described herein.

With reference back to FIG. 2, the top portion 20 of the corrugated box10 may also be designed with a second perforation feature 56. The secondperforation feature 56 is defined by a series of perforations 56 a(e.g., weak points) that help a user with removal thereof, such that thesecond perforation feature 56 is removable from a remainder of the backwall 24 of the top portion 20.

As detailed further herein, the second perforation feature 56 may beremovable to provide a user access to a handle feature 70 when the box10 is converted into a bag-in-box dispenser, such as shown in FIG. 12.Additionally, however, in some embodiments, the second perforationfeature 56 may be shaped similarly as the first perforation feature 50(e.g., form an elongated shape 55) and, thus, may enable the top portion20 to be positioned/slid back onto the bottom portion 30 with either thefront wall 22 or the back wall 24 facing the same direction as the frontwall 32 of the bottom portion 30 (with the dispensing valve 92 installedin the dispensing position). In such a regard, the second perforationfeature 56 may (like the first perforation feature) extend to a bottomedge 23 c of the back wall 24 of the top portion 20.

In some embodiments, the second perforation feature 56 is aligned with ahandle feature 70 of the bottom portion 30 and forms a shape 55 thatenables a user to access the handle feature 70 when the top portion 20is positioned over the bottom portion 30 (e.g., shown in FIG. 12). Inthis regard, the handle feature 70 (which is shown in FIG. 4), isdefined on the back wall 34 of the bottom portion 30. The handle feature70 is defined by one or more perforations on the back wall 24 and iseither already formed into or capable of being formed into a handle forreceiving a user's hand or fingers such as for use during pouring liquidfrom the bag stored in the box after the box has been converted into thebag-in-box dispenser (e.g., shown in FIG. 12). In the illustratedembodiment of FIG. 4, the handle feature 70 defines a first portion 72 aand an adjacent second portion 72 b that can be removed or pushed intothe bottom portion 30 to enable insertion of a user's hand orfingers—thereby forming a handle (although other designs arecontemplated to form a handle). In some embodiments, one or moreportions of the handle feature 70 may be solid cut (e.g., opposed to aseries of perforations). For example, a center line 70 a (shown in FIG.5) may be solid cut, such as may aid in a user's or machine's formationof the handle feature 7- thereafter.

Like the first perforation feature 50, in some embodiments, the secondperforation feature 56 may be spaced apart from a top edge 24 a of thefront wall 24 to maintain a desired rigidity, such that may otherwise becompromised if one or more perforations (e.g., weak points) werepositioned at or too near the top edge 24 a of the back wall 24 of thetop portion 20.

Returning to FIG. 2, the top portion 20 may further define a secondfinger access feature 58 (further shown in FIG. 8) positioned adjacentto the second perforation feature 56. The second finger access feature58 may be at least partially defined by a series of perforations 56 b(e.g., a separate line of perforations than the second perforationfeature) and may be removable separately from the second perforationfeature 56 to enable easier access for a user to remove the secondperforation feature 56. Though the second finger access feature 58 isshown defined on the back wall 24, in various embodiments, the secondfinger access feature 58 may be formed on one or more walls or topflaps. Along similar lines, though the second finger access feature 58is shown as a semi-circle, any suitable shape may be used. Withreference to FIG. 8, like with the second perforation feature 56, a top79 b of the second finger access feature 58 may be spaced apart from atop edge 24 a of the back wall 24, such as shown by D_(FA2).

In some embodiments, the box 10 (or portions thereof) may be formed ofsingle-walled corrugate. However, in other embodiments, the box 10 (orportions thereof) may be formed of double-walled corrugate to addstrength to the box 10, such as may be beneficial for individual boxshipping and/or passing the test standards noted herein. In someembodiments, both the top portion 20 and the bottom portion 30 areformed of double-walled corrugate. In some embodiments, the box 10 (orportions thereof) may be formed of additional layers of corrugate (e.g.,triple-walled corrugate, or more), such as may be beneficial for furtherincreased strength. In some embodiments, the box 10 (or portionsthereof) may be formed of other types of material, such as cartonboard,microflute corrugate, etc.

FIG. 6 illustrates an example process an end user goes through toconvert the now shipped box 10 into a bag-in-box dispenser. First, auser removes the first perforation feature 50 (e.g., by using the firstfinger access portion 58—although in some embodiments there may not be afinger access portion). In embodiments, with a finger access portion 58the user may insert their finger into the first finger access portion 58and pull the first finger access portion 58 up and/or off and the firstperforation feature 50 upwardly (e.g., step 110). With reference to FIG.7, removal of the first perforation feature 50 reveals, at leastpartially, the cut-out feature 51 of the bottom portion 30. Notably,while not shown in FIG. 6, the same process can be repeated to removethe second perforation feature 56, such as by using the second fingeraccess portion 58 (e.g., shown in completed form in FIG. 8). Returningto FIG. 6, according to step 120, a user can now lift (e.g., raise) thetop portion 20 from the bottom portion 30 (e.g., shown also in FIG. 9).With reference to FIG. 10, removal of the first perforation feature 50reveals the dispensing valve 92 and the cut-out feature 51 of the bottomportion 30. With the top portion 20 raised, a user can reach in and pullthe dispensing valve 92 out and position it within the cut-out feature51 and in to the dispensing position. Then, the user can simply lowerthe top portion 20 over the installed dispensing valve 92, such as shownin FIG. 11, to convert it into the bag-in-box dispenser that can now beutilized for pouring liquid from the stored bag 90 (e.g., step 130). Asnoted herein, the user can also form the handle by pushing in portions72 a and 72 b of the handle feature 70 and thereafter utilize the handleto aid in pouring and/or full evacuation of the liquid (e.g., referenceFIG. 12). In some embodiments, the converted bag-in-box dispenser maydefine an internal gap within the openings of the top and bottomportions 20, 30. Said differently, and with reference to FIG. 11, afterthe top portion 20 is slid back down onto the bottom portion 30, theremay be extra space which is illustrated by the distance between thebottom edge 23 a of the front wall 22 of the top portion 20 and thebottom edge 32 a of the front wall 32 of the bottom portion 30.

Notably, a benefit for positioning the dispensing valve 92 closer to thetop edge of the front wall 22 is that a user can visually confirmpouring accuracy when holding the box 10. A further benefit of slidingthe top portion 20 back over the installed dispensing valve 92 is thatthe top portion 20 may aid in pour control as it may help keep thedispensing valve 92 positioned within the cut-out feature 51, such asvia an interference fit—as shown in FIG. 11. Notably, however, someusers may desire not to reposition/slide the top portion 20 back overthe bottom portion 30, and just use the bottom portion 30 as thebag-in-box dispenser and, thus, some embodiments provide increasedversatility.

Example Flowchart(s)

Embodiments of the present invention provide methods and systems forforming a box, shipping the box with a bag stored therein, andconverting the box into the bag-in-box dispenser, according to variousembodiments described herein. In this regard, associated systems andmethods for manufacturing, shipping, and forming example box designs andconverting into corresponding bag-in-box dispensers described herein arecontemplated by some embodiments of the present invention. Such systemsand methods may include various machines and devices, including forexample box forming devices (e.g., for folding, gluing, and/or tapingboxes, among other things) and/or corrugators. In this regard, knowncorrugators utilize web product (e.g., liner) and flute medium to formcorrugated web product (which may be formed into any number of layeredcorrugate, such as conventional corrugate (liner, flute medium, liner)or double-walled corrugate (liner, flute medium, liner, flute medium,and liner)). The formed corrugated web product may then be cut (e.g.,scored, sliced, perforated, etc.) as needed to form a box blank of thedesired box (e.g., any of the box designs described herein). An examplecorrugator is further described in U.S. Publication No. 2019/0016081,which was filed Jul. 12, 2018, and entitled “Controls for Paper, Sheet,and Box Manufacturing Systems”, the contents of which is incorporated byreference herein in its entirety.

Various examples of the operations performed in accordance with someembodiments of the present invention will now be provided with referenceto FIG. 13. In this regard, FIG. 13 illustrates a flowchart according toan example method for forming a box, shipping the box with a bag storedtherein, and converting the box into the bag-in-box dispenser accordingto an example embodiment 200. The operations illustrated in anddescribed with respect to FIG. 13 may, for example, be performed by,with the assistance of, and/or under the control of one or more of auser or a machine for performing the operation (e.g., a corrugator forforming the corrugated box blanks, a box-forming machine for forming thebox or portions thereof, a bag loading machine for loading the bag intothe box, etc.).

Operation 202 may comprise forming the corrugated web product, andoperation 204 may comprise forming the box blank, such as may includeboth the top portion 20 and the bottom portion 30. As noted above, suchoperations may be performed by various known machines/devices, such as acorrugator.

Operation 206 may comprise erecting (e.g., forming) the top portion,which may occur using a box forming machine and/or via a user.Similarly, operation 208 may comprise erecting (e.g., forming) thebottom portion, which may also occur using a box forming machine and/ormanually via a user. Operation 210 may include inserting the bag ofliquid into the bottom portion and forming the completed box with storedbag therein by positioning the top portion thereover. In someembodiments, the operation 210 may include securing the top portion tothe bottom portion, such as via tape, adhesive, etc. This may becompleted by a machine/device and/or via a user.

Operation 212 may comprise shipping the box with stored bag therein,such as using individual box shipping means described herein. Then, suchas upon arrival at the final destination, operation 214 may compriseconverting the box into the bag-in-box dispenser, such as describedfurther herein. This may be performed using a machine/device and/or viaa user.

CONCLUSION

Many modifications and other embodiments of the inventions set forthherein may come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the embodiments of the invention are not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theinvention. Moreover, although the foregoing descriptions and theassociated drawings describe example embodiments in the context ofcertain example combinations of elements and/or functions, it should beappreciated that different combinations of elements and/or functions maybe provided by alternative embodiments without departing from the scopeof the invention. In this regard, for example, different combinations ofelements and/or functions than those explicitly described above are alsocontemplated within the scope of the invention. Although specific termsare employed herein, they are used in a generic and descriptive senseonly and not for purposes of limitation.

1. A corrugated box for shipping a bag of liquid stored therein andconverting into a bag-in-box dispenser, the box comprising: a topportion comprising a plurality of walls, wherein the top portion definesan opening, wherein the top portion includes: a perforation featuredefined on a first wall of the plurality of walls, wherein theperforation feature is defined by a series of perforations and isremovable from a remainder of the first wall, wherein the perforationfeature is configured to enable a dispensing valve of the bag to extendpast or through the first wall of the top portion when the box isconverted into the bag-in-box dispenser and the perforation feature isremoved; and a bottom portion comprising a plurality of walls, whereinthe bottom portion defines an opening configured to receive the bag ofliquid, wherein the bottom portion is sized to fit within the opening ofthe top portion, wherein the bottom portion defines: a cut-out featurethat defines a portion of a first wall of the plurality of walls of thebottom portion that is at least one of pre-removed or capable of beingremoved from a remainder of the first wall of the bottom portion,wherein the cut-out feature is positioned on the first wall of thebottom portion to align with the perforation feature of the top portionwhen the bottom portion is received within the top portion, wherein thecut-out feature is configured to enable the dispensing valve to extendpast or through the first wall of the bottom portion when the box isconverted into the bag-in-box dispenser.
 2. The box of claim 1, whereinthe first wall of the top portion defines a top edge, a bottom edge anda length therebetween, and wherein the perforation feature extends froma position at or above a center position along the length to the bottomedge.
 3. The box of claim 2, wherein the perforation feature defines anelongated shape that increases in width in a direction leading to thebottom edge of the first wall of the top portion.
 4. The box of claim 2,wherein a width of the perforation feature proximate the bottom edge ofthe first wall of the top portion is sized to receive one or more piecesof tape, wherein the tape is used to secure the top portion to thebottom portion.
 5. The box of claim 4, wherein removal of theperforation feature results in the removal of the one or more pieces oftape to enable movement of the top portion relative to the bottomportion.
 6. The box of claim 1, wherein the first wall of the topportion has a top edge, a bottom edge and a length therebetween, andwherein the perforation feature defines an elongated shape with aperforation feature length that extends from a position at or above acenter position along the length toward the bottom edge, wherein theperforation feature length is greater than a corresponding lengthcharacteristic of the dispensing valve such that the top portion may belifted upwardly from the bottom portion and a user can pull thedispensing valve through an opening formed in the first wall of the topportion by removal of the perforation feature.
 7. The box of claim 1,wherein the first wall of the top portion has a top edge, wherein theperforation feature is positioned on the first wall of the top portionsuch that it is spaced apart from the top edge.
 8. The box of claim 1,wherein the cut-out feature defines a shape that corresponds to aportion of the dispensing valve such that the cut-out feature holds thedispensing valve in position when the box is converted into thebag-in-box dispenser.
 9. The box of claim 8, wherein the cut-out featureis defined along a top edge of the first wall of the bottom portion. 10.The box of claim 1, wherein the top portion further defines a fingeraccess feature positioned adjacent to the perforation feature.
 11. Thebox of claim 1, wherein the perforation feature is a first perforationfeature, wherein the top portion further includes a second perforationfeature defined on a second wall of the plurality of walls of the topportion, wherein the second wall of the top portion is opposite thefirst wall of the top portion, wherein the second perforation feature isdefined by a series of perforations and is removable from a remainder ofthe second wall, and wherein the bottom portion further comprises ahandle feature that is defined on a second wall of the plurality ofwalls of the bottom portion, wherein the second wall of the bottomportion is opposite the first wall of the bottom portion, wherein thehandle feature is defined by one or more perforations on the second wallof the bottom portion, wherein the handle feature is positioned on thesecond wall of the bottom portion to align with the second perforationfeature of the top portion when the bottom portion is received withinthe top portion.
 12. The box of claim 11, wherein the second wall of thetop portion has a top edge, a bottom edge and a length therebetween, andwherein the second perforation feature extends from a position at orabove a center position along the length to the bottom edge.
 13. The boxof claim 1, wherein the bottom portion defines a side flap that isattached to an outside surface of one of the plurality of walls so toform the opening of the bottom portion, wherein the side flap isattached to the outside surface so as to be separated from the storedbag within the box to avoid damage to the stored bag during shipping.14. The box of claim 1, wherein the box is configured to store the bagof liquid with volume ranging from 2 liters to 10 liters and keep thebag from damage or leaking during individual box shipping.
 15. The boxof claim 14, wherein the box is designed to store the bag and passindividual box shipping test standards, including at least the 2018International Safe Transit Association (ISTA) Series 6-Amazon.com-ShipIn Own Container (SIOC) test protocol for Type A.
 16. The box of claim1, wherein the box is designed to survive individual box shipping suchthat the perforation feature is intact and the bag is free of damage orleaking so as to enable conversion of the box into the bag-in-boxdispenser thereafter.
 17. A system including the box of claim 1, whereinthe system further includes the bag of liquid including the dispensingvalve, wherein the bag is stored within the opening of the bottomportion of the box.
 18. A box blank for a corrugated box for shipping abag of liquid stored therein and converting the box into a bag-in-boxdispenser, wherein the box blank is formed of corrugate and comprises: atop portion comprising a plurality of panels, wherein the top portion,when formed into a box top portion, defines an opening, wherein the topportion defines: a perforation feature defined on a first panel of theplurality of panels, wherein the perforation feature is defined by aseries of perforations and is removable from a remainder of the firstpanel, wherein the perforation feature is configured to enable adispensing valve of the bag to extend past or through the first panelwhen the box is converted into the bag-in-box dispenser and theperforation feature is removed; and a bottom portion comprising aplurality of panels, wherein, when formed into a box bottom portion, thebottom portion defines an opening configured to receive the bag ofliquid and the bottom portion is sized to fit within the opening of thetop portion, wherein the bottom portion defines: a cut-out feature thatdefines a portion of a first panel of the plurality of panels of thebottom portion that is at least one of pre-removed or capable of beingremoved from a remainder of the first panel of the bottom portion,wherein the cut-out feature is positioned on the first panel of thebottom portion to align with the perforation feature of the top portionwhen the bottom portion is received within the top portion, wherein thecut-out feature is configured to enable the dispensing valve to extendpast or through the first panel of the bottom portion when the box isconverted into the bag-in-box dispenser.
 19. The box blank of claim 18,wherein the first panel of the top portion defines a top edge, a bottomedge and a length therebetween, and wherein the perforation featureextends from a position at or above a center position along the lengthto the bottom edge.
 20. The box blank of claim 19, wherein theperforation feature defines an elongated shape that increases in widthin a direction leading to the bottom edge of the first panel of the topportion.
 21. The box blank of claim 18, wherein the first panel of thetop portion defines a top edge, a bottom edge and a length therebetween,and wherein the perforation feature defines an elongated shape with aperforation feature length that extends from a position at or above acenter position along the length toward the bottom edge, wherein theperforation feature length is greater than a corresponding lengthcharacteristic of the dispensing valve such that the formed box topportion may be lifted upwardly from the formed box bottom portion and auser can pull the dispensing valve through an opening formed in thefirst panel of the formed box top portion by removal of the perforationfeature.
 22. The box blank of claim 18, wherein the first panel of thetop portion defines a top edge, wherein the perforation feature ispositioned on the first panel such that it is spaced apart from the topedge.
 23. The box blank of claim 18, wherein the cut-out feature definesa shape that corresponds to a portion of the dispensing valve such thatthe cut-out feature is configured to hold the dispensing valve inposition when the box is converted into the bag-in-box dispenser. 24.The box blank of claim 18, wherein the perforation feature is a firstperforation feature, wherein the top portion further includes a secondperforation feature defined on a second panel of the plurality of panelsof the top portion, wherein the second panel of the top portion isopposite the first panel of the top portion, wherein the secondperforation feature is defined by a series of perforations and isremovable from a remainder of the second panel, and wherein the bottomportion further comprises a handle feature that is defined on a secondpanel of the plurality of panels of the bottom portion, wherein thesecond panel of the bottom portion is opposite the first panel of thebottom portion, wherein the handle feature is defined by one or moreperforations on the second panel of the bottom portion, wherein thehandle feature is positioned on the second panel of the bottom portionto align with the second perforation feature of the top portion when thebox bottom portion is received within the box top portion.
 25. The boxblank of claim 18, wherein the box, when formed, is configured to storethe bag of liquid with volume ranging from 2 liters to 10 liters andkeep the bag from damage or leaking during individual box shipping. 26.The box blank of claim 25, wherein the box, when formed, is designed tostore the bag and pass individual box shipping test standards, includingat least the 2018 International Safe Transit Association (ISTA) Series6-Amazon.com-Ship In Own Container (SIOC) test protocol for Type A. 27.The box blank of claim 18, wherein the box, when formed, is designed tosurvive individual box shipping such that the perforation feature isintact and the bag is free of damage or leaking so as to enableconversion of the box into the bag-in-box dispenser thereafter.
 28. Amethod of manufacturing a box blank for a corrugated box for shipping abag of liquid stored therein and converting into a bag-in-box dispenser,the method comprising: forming corrugated web product; cutting out a topportion of the box blank from the corrugated web product, wherein thetop portion comprises a plurality of panels, wherein the top portion,when formed into a box top portion, defines an opening, wherein the topportion defines: a perforation feature defined on a first panel of theplurality of panels, wherein the perforation feature is defined by aseries of perforations and is removable from a remainder of the firstpanel, wherein the perforation feature is configured to enable adispensing valve of the bag to extend past or through the first panelwhen the box is converted into the bag-in-box dispenser and theperforation feature is removed; and cutting out a bottom portion of thebox blank from the corrugated web product, wherein the bottom portioncomprises a plurality of panels, wherein, when formed into a box bottomportion, the bottom portion defines an opening configured to receive thebag of liquid and the bottom portion is sized to fit within the openingof the top portion, wherein the bottom portion defines: a cut-outfeature that defines a portion of a first panel of the plurality ofpanels of the bottom portion that is at least one of pre-removed orcapable of being removed from a remainder of the first panel of thebottom portion, wherein the cut-out feature is positioned on the firstpanel of the bottom portion to align with the perforation feature of thetop portion when the bottom portion is received within the top portion,wherein the cut-out feature is configured to enable the dispensing valveto extend past or through the first panel of the bottom portion when thebox is converted into the bag-in-box dispenser.
 29. The method of claim28 further comprising: erecting the box top portion; and erecting thebox bottom portion.
 30. The method of claim 29 further comprising:inserting the bag of liquid into the opening of the box bottom portion;and sliding the box top portion over the box bottom portion with the bagstored therein.